JP2024054742A - Optical components and vehicle lighting fixtures - Google Patents

Abstract

A new lightweight optical component is provided.
[Solution] The optical component includes a shade 16e made of a metal material for forming a cut line of a light distribution pattern by blocking a portion of the light emitted from the light source, and a reflector 16 made of a resin material and having a pair of reflective surfaces for reflecting a portion of the light emitted from the light source forward of the vehicle. The shade 16e is disposed between the pair of reflective surfaces 16f and is integrated with the reflector 16.
[Selected figure] Figure 4

Description

The present invention relates to optical components, for example, optical components used in vehicle lighting.

Conventionally, there has been known a vehicle headlamp equipped with a light-emitting element array made of multiple semiconductor light-emitting elements, each configured to be able to illuminate multiple individual illumination areas divided in the left-right direction above the horizontal line. For example, a vehicle headlamp has been devised that includes a light-emitting element array in which multiple light-emitting elements configured to be able to be individually lit, each of which has an individual illumination area that constitutes a high beam light distribution pattern, are mounted in a row on a substrate, a projection lens disposed in front of the light-emitting element array, and a reflector disposed below the light-emitting element array (see Patent Document 1).

International Publication No. WO 16/013447

However, the reflector provided in the vehicle headlamp mentioned above is a single component made entirely of metal, which increases the weight of the component and tends to increase the material cost. On the other hand, when sunlight enters from the outside through the projection lens and is concentrated inside the lamp, the light-concentrating part becomes very hot, so the part that can become the light-concentrating part must be heat-resistant.

The present invention was made in consideration of these circumstances, and one of its exemplary objectives is to provide a new optical component that is lightweight while satisfying desired performance such as light distribution and heat resistance.

In order to solve the above problems, an optical component according to one embodiment of the present invention includes a shade made of a metal material for forming a cut line in a light distribution pattern by blocking a portion of the light emitted from the light source, and a reflector made of a resin material and having a pair of reflecting surfaces for reflecting a portion of the light emitted from the light source forward of the vehicle. The shade is disposed between the pair of reflecting surfaces and is integrated with the reflector.

According to this aspect, the reflector can be made of a resin material while improving the heat resistance of the shade that constitutes the optical component, thereby making it possible to reduce the weight of the optical component equipped with a shade that contributes to the formation of a desired light distribution pattern.

Another aspect of the present invention is a vehicle lamp. This vehicle lamp includes a light source consisting of a light-emitting element, an optical component, and a projection lens that projects the light emitted from the light source forward of the vehicle. The distance between the reflecting surface and the light source is greater than the distance between the shade and the light source.

According to this embodiment, the thermal effect of the light from the light source on the reflecting surface of the reflector can be made smaller than the thermal effect on the shade.

The shade may be positioned below the reflective surface.

The light source is arranged so that the light emission surface faces the front of the vehicle, and may have a plurality of first light-emitting elements arranged in a horizontal direction to form a light distribution pattern mainly for low beam, and a plurality of second light-emitting elements arranged in a horizontal direction to form a light distribution pattern mainly for high beam. The shade may be arranged in a region between the first light-emitting elements and the second light-emitting elements when the light source is viewed from the front of the vehicle. This allows the shade to form a cut line for the light distribution pattern for low beam.

The reflective surface may reflect light emitted laterally from the first light-emitting element.

The first light-emitting element may be arranged above the second light-emitting element.

Any combination of the above components, and expressions of the present invention converted between manufacturing methods, devices such as lamps and lighting, light-emitting modules, light sources, etc. are also valid aspects of the present invention.

The present invention makes it possible to realize new optical components that are lightweight.

1 is a side view showing a schematic configuration of a vehicle lamp according to an embodiment of the present invention; 1 is a perspective view of a main part of a vehicle lighting unit according to an embodiment of the present invention; FIG. 3 is an exploded perspective view of the vehicle lighting unit shown in FIG. 2 . FIG. 2 is an exploded perspective view of the reflector according to the embodiment. 5 is an exploded perspective view of the reflector according to the embodiment, seen from a different direction from that in FIG. 4. FIG. 4 is a schematic diagram of a vehicle lighting unit as viewed from the side for explaining the positional relationship between a main part of a reflector and a light source. FIG. FIG. 2 is a schematic diagram of a reflector and a light source viewed from above.

The present invention will be described below with reference to the drawings based on preferred embodiments. The same or equivalent components, parts, and processes shown in each drawing will be given the same reference numerals, and duplicated descriptions will be omitted as appropriate. Furthermore, the embodiments are illustrative rather than limiting the invention, and all of the features and combinations thereof described in the embodiments are not necessarily essential to the invention.

Figure 1 is a side view showing the schematic configuration of a vehicle lamp according to this embodiment. Figure 2 is a perspective view of the main parts of a vehicle lamp unit according to this embodiment. Figure 3 is an exploded perspective view of the vehicle lamp unit shown in Figure 2. The vehicle lamp unit 10 shown in Figures 2 and 3 is a vehicle headlamp provided at the front of the vehicle, and is configured to be able to form both low beam and high beam light distribution patterns.

The vehicle lighting fixture 100 comprises a lamp body 2, an outer lens 4 that covers the opening of the lamp body 2, a vehicle lighting unit 10 provided in a lamp chamber 6 surrounded by the lamp body 2 and the outer lens 4, and an aiming mechanism 8 that holds the vehicle lighting unit 10 so that it can be aimed. The vehicle lighting unit 10 comprises a projection lens 12 that projects light emitted from a light source forward of the vehicle, a lens holder 14, a reflector 16, a circuit board 20, a heat sink 22, and a fan 24.

The lens holder 14 has a substantially cylindrical lens holding portion 14a and three legs 14b protruding from the lens holding portion 14a toward the rear of the vehicle. The projection lens 12 is a transparent member in which a lens body portion 12a that controls the optical path of light emitted from the light source and a flange-shaped mounting portion 12b that protrudes outward from the outer periphery of the lens body portion 12a are integrally formed. The projection lens 12 is held in the lens holder 14 by aligning the mounting portion 12b of the projection lens 12 with the lens holding portion 14a of the lens holder 14 and fixing them with screws 26. The projection lens 12 is manufactured by injection molding using a resin material that is highly transparent and heat resistant, such as acrylic or polycarbonate.

The reflector 16 according to this embodiment is an optical component that is partially made of a resin material and partially made of a metal material in order to reduce costs and weight. The reflector 16 has a horizontally long base surface portion 16a facing the front-rear direction, side reflection portions 16c that are provided so as to protrude forward from both the left and right sides of an opening 16b formed in the center of the reflector 16, an upper reflector 16d in which the inner surface of the beam-shaped portion above the opening 16b serves as a reflection surface, and a shade 16e that protrudes forward from the lower edge of the opening 16b.

The circuit board 20 has a first light source 20a in which a plurality of light-emitting elements 21a for mainly forming a low-beam light distribution pattern are arranged in a horizontal row, a second light source 20b in which a plurality of light-emitting elements 21b for mainly forming a high-beam light distribution pattern are arranged in a horizontal row, and a drive circuit 20c for driving each light-emitting element. The second light source 20b is arranged adjacent to the first light source 20a. The first light source 20a is located on the upper stage side, and the second light source 20b is located on the lower stage side. In other words, the light-emitting element 21a is arranged above the light-emitting element 21b. The first light source 20a and the second light source 20b are arranged so that the light emission surface faces the front of the vehicle.

The drive circuit 20c is a combination of passive elements such as capacitors and coils, active elements such as transistors and diodes, IC chips, memory, etc., and is mounted in an area of the circuit board 20 below the area in which the light sources 20a and 20b are mounted.

The light emitted from the first light source 20a passes through the opening 16b of the reflector 16. At that time, some of the light is reflected by the reflective surfaces of the side reflector 16c, the upper reflector 16d, and the shade 16e, and is irradiated toward the projection lens 12 with light distribution control performed. The projection lens 12 projects the light that arrives directly from the first light source 20a and the light that has been distribution-controlled by each reflective surface as a desired light distribution pattern in front of the vehicle. As a result, on the screen in front of the vehicle, the area mainly below the horizon is irradiated with light of the low beam light distribution pattern.

Shade 16e is disposed in the area between light-emitting element 21a and light-emitting element 21b when the light source is viewed from the front of the vehicle. As a result, shade 16e functions to form a cut line of the low beam light distribution pattern by blocking a portion of the light emitted from first light source 20a.

Similarly, the light emitted from the second light source 20b passes below the shade 16e of the reflector 16. At that time, a portion of the light is reflected by the reflective surface on the lower side of the shade 16e and is irradiated toward the projection lens 12 with light distribution control performed. The projection lens 12 projects the light that arrives directly from the second light source 20b and the light that has been distributed and controlled by each reflective surface as a desired light distribution pattern in front of the vehicle. As a result, the area above the horizon on the screen in front of the vehicle is mainly irradiated with light of the high beam light distribution pattern. In this way, the projection lens 12 projects a light distribution pattern in front of the lamp using light emitted from at least one of the first light source 20a and the second light source 20b.

When each of the above light sources is driven, heat is generated from the light sources, the components constituting the drive circuit 20c, wiring, etc. Some of the heat generated from the light sources 20a, 20b, etc. is transferred to the heat sink 22 and is released to the outside from each part of the heat sink 22, particularly the fins 22a. At this time, the cooling air generated by the rotation of the cooling fan 24 flows along the fins 22a, improving heat dissipation. The lens holder 14 is fixed to the heat sink 22 with screws 28.

Next, the reflector 16 will be described in detail. Fig. 4 is an exploded perspective view of the reflector according to this embodiment. Fig. 5 is an exploded perspective view of the reflector according to this embodiment as seen from a different direction than Fig. 4. The reflector 16 according to this embodiment is formed by assembling a first part 17a of a shade 16e made of a metal material and a second part 17b made of a resin material. The second part 17b is made of a base surface part 16a, a pair of side reflecting parts 16c, and an upper reflector 16d.

The pair of side reflecting portions 16c each have a reflecting surface 16f. The pair of reflecting surfaces 16f face each other and mainly reflect a portion of the light emitted to the side from the light emitting element 21a of the first light source 20a toward the front of the vehicle. The shade 16e is disposed below the reflecting surface 16f. The shade 16e is disposed between the pair of reflecting surfaces 16f and is integrated with the reflector 16. The shade 16e is integrated with the reflector by inserting the positioning pin 16g and the heat crimping pin 16h provided on the lower part of the second part 17b into the corresponding holes 16j and 16k of the first part 17a and melting the heat crimping pin 16h.

This improves the heat resistance of the shade 16e that constitutes the reflector 16, while allowing part of the reflector 16 to be made of a resin material, making it possible to reduce the weight of the reflector 16 equipped with the shade 16e that contributes to the formation of the desired light distribution pattern.

Next, the positional relationship between the reflector 16 and each light source will be described. Figure 6 is a schematic diagram of the vehicle lighting unit 10 viewed from the side to explain the positional relationship between the main parts of the reflector 16 and the light sources. Figure 7 is a schematic diagram of the reflector and light sources viewed from above.

As shown in Figures 6 and 7, in the vehicle lighting unit 10, the distance D1 between the light-emitting element 21a and the reflective surface 16f and the distance D2 between the light-emitting element 21a and the reflective surface of the upper reflector 16d are greater than the distance D3 between the shade 16e and the light-emitting element 21a. This makes it possible to make the thermal effect of the light from the first light source 20a on each reflective surface of the reflector 16 smaller than the thermal effect on the shade 16e. As a result, if the shade 16e is made of a heat-resistant metal or ceramic material, the other parts of the reflector 16 can be made of an inexpensive and lightweight resin material.

In addition, as shown in FIG. 6, when sunlight S enters from the outside through the projection lens 12, the tip of the shade 16e, which is located in a place in the vehicle lighting unit 10 where light is likely to be collected, can be prevented from melting by making the shade 16e out of a heat-resistant material.

Although the present invention has been described above with reference to the above-mentioned embodiment, the present invention is not limited to the above-mentioned embodiment, and suitable combinations or substitutions of the configurations of the embodiments are also included in the present invention. In addition, it is possible to suitably rearrange the combinations and processing order in the embodiments based on the knowledge of those skilled in the art, and to make modifications to the embodiments such as various design changes, and embodiments with such modifications are also included in the scope of the present invention.

10 Vehicle lighting unit, 12 Projection lens, 16 Reflector, 16a Base surface portion, 16c Side reflection portion, 16d Upper reflector, 16e Shade, 16f Reflection surface, 17a First part, 17b Second part, 20 Circuit board, 20a First light source, 20b Second light source, 21a Light emitting element, 21b Light emitting element, 100 Vehicle lighting unit.

Claims (6)

A shade made of a metal material for forming a cut line of the light distribution pattern by blocking a part of the light emitted from the light source;
a reflector that is made of a resin material and has a pair of reflective surfaces that reflect a portion of the light emitted from the light source forward of the vehicle;
An optical component, wherein the shade is disposed between the pair of reflecting surfaces and is integrated with the reflector. A light source consisting of a light emitting element;
The optical component according to claim 1 ;
a projection lens that projects the light emitted from the light source forward of the vehicle;
A vehicle lamp, comprising: a reflecting surface and a light source, the reflecting surface and the light source being spaced from each other; a reflecting surface and a light source being spaced from each other; The vehicle lamp according to claim 2, characterized in that the shade is disposed below the reflective surface. The light source is disposed so that a light emission surface faces forward of the vehicle,
A plurality of first light-emitting elements arranged in a horizontal direction for mainly forming a light distribution pattern for low beam;
a plurality of second light-emitting elements arranged in a horizontal direction for mainly forming a high beam light distribution pattern;
4. The vehicle lamp according to claim 2, wherein the shade is disposed in a region between the first light-emitting element and the second light-emitting element when the light source is viewed from the front of the vehicle. The vehicle lamp according to claim 4, characterized in that the reflective surface reflects light emitted laterally from the first light-emitting element. The vehicle lamp according to claim 4, characterized in that the first light-emitting element is arranged above the second light-emitting element.

Images